Encapsulation of oleophilic substances and compositions produced thereby

Abstract

Multiple micro-encapsulations of a high concentration oleophilic substance using heat to set the primary particle renders the composition suitable for the production of free-flowing powders or beadlets. Microencapsulation involves forming an emulsion out of the oleophilic substance and a polymer, and then use heat setting and/or cross-linking the polymer encapsulates the oleophilic composition. This process is then repeated with a second polymer or third polymer, and with or without cross-linked via the same or different mechanism to further protect the oleophilic substance.

Description

CROSS-REFERENCE APPLICATION

This application is a continuation-in-part of U.S. patent application Ser. No. 08/269,720, filed Jul. 1, 1994 now abandoned.

FIELD OF THE INVENTION

The invention relates to encapsulation of oleophilic substances (as used herein the term "oleophilic" is to embrace fat- and oil-soluble substances as well as fats and oils), and to compositions produced by this process. In particular, the invention relates to the preparation of high potency, dry and free-flowing vitamin powders/beadlets using multiple microspheric and/or microencapsulation techniques.

BACKGROUND OF THE INVENTION

Oleophilic substances, and in particular fat-soluble vitamins such as A, D, E and K, have had limited incorporation into dry materials because of their oil-like nature. Accordingly, oleophilic substances have tended to be macroencapsulated and delivered as units of coated oil. Unfortunately, however, such delivery drastically restricts the applications for which these oleophilic substances are suitable. For example, current commercial techniques can only produce concentrations of vitamin E which range up to 50% by weight.

The present invention overcomes the limitations inherent in the prior art encapsulation techniques and allows for production of high potency vitamins in a free flowing powder form. Such a form allows for delivery into multiple vitamin tablets or foods, such as cereal, and provides the advantages of reducing tablet size or the bulk required for subsequent delivery. Of particular interest is high potency Vitamin E in which Vitamin E forms greater than about 50% by weight of a dry powder or beadlet.

The prior art, as represented by Lim, et al., U.S. Pat. No. 4,389,419, issued Jun. 21, 1983, the contents of which are herein incorporated by reference, describes the formation of an emulsion consisting of a continuous phase aqueous solution of an alkali metal alginate, and optionally, a water-soluble alcohol-insoluble filler such as a polysaccharide, and a dispersed phase of an oleophilic substance. The emulsion thus produced is then formed into droplets which are emersed into an alcoholic solution of multi-valent cations, to produce a water-insoluble shape-retaining alginate matrix filled with precipitated polysaccharide and enclosing plural oil droplets.

The Lim, et al. approach differs markedly from that of the subject invention in which an oleophilic substance is incorporated into a primary polymer containing solution, and then solidified under mixing conditions to encapsulate the fat-soluble substance and form an encapsulated fat-soluble composition. Through the use of mixing conditions in forming the primary particle, far greater concentrations of oleophilic substances relative to those achieved by Lim, et al. can be realized. As stated by Lim, et al., the amount of oil may range from between 1% up to nearly 30%. However, at the higher end of this range, the stability of the Lim, et al. oil-in-water emulsion is decreased and the quality of the Lim, et al. microcapsule is reduced.

Additionally, the Lim, et al. droplets need to be removed from the alcoholic solution and washed, or otherwise treated, to remove any residual alcohol, thus requiring extra production steps.

Another markedly different approach employed for encapsulating vitamin or mineral nutrients, such as thiamine, is described by Hall, et al., U.S. Pat. No. 4,182,778, issued Jan. 8, 1980, the contents of which are herein incorporated by reference.

Hall, et al. describes encapsulation by fluidizing the nutrient in a gaseous stream and contacting the nutrient with finely atomized droplets of a coating solution. Nowhere, however, is the application of the Hall, et al. suggested for use with oleophilic substances.

As described below, the concentration of the oleophilic substance in the subject invention typically ranges from about 30% to about 90% based on the dry weight percentage of the final encapsulated oleophilic composition. These percentages are far superior to those described by Lim, et al., and form a major breakthrough over the current state of the art which only allows percentages of vitamin E to reach about 50%. Thus, the subject invention fulfills a long-felt need in the art for a high potency encapsulated oleophilic composition.

SUMMARY OF THE INVENTION

The invention provides a method for producing a composition which encapsulates an oleophilic substance. This method comprises incorporating an oleophilic substance into a primary polymer-containing solution, and solidifying the primary polymer under mixing conditions to encapsulate the oleophilic substance within the polymer and form the composition.

Typically, the primary polymer is a cellulose, such as methylcellulose and hydroxypropyl methylcellulose, and the oleophilic substance is a fat-soluble vitamin, such as vitamin A, D, E, and K. Preferably, the concentration of the oleophilic substance ranges from about 30% to about 90% based on a dry weight percentage of the final encapsulated composition.

Also provided is a preferred method for producing a composition encapsulating an oleophilic substance. This method involves incorporating an oleophilic substance into a primary polymer-containing solution, solidifying the primary polymer under mixing conditions to encapsulate the oleophilic substance within the polymer and form a primary particle, and adding a secondary polymer under mixing conditions to further encapsulate at least one primary particle within the secondary polymer and form the composition (secondary particle). Of course, multiple primary particles may be encapsulated to form a single secondary particle, and the mixing conditions may vary between the first and second encapsulation.

As with the first method, the primary polymer is usually a cellulose, such as methylcellulose and hydroxypropyl methylcellulose. The secondary polymer is generally a cellulose, cellulose derivative, maltodextrin, such as a maltodextrin having a dextrose equivalent value of about 18, alginate, calcium lactate, acacia, gelatin, such as fish gelatin, or modified starch, such as hydroxypropyl starch or pregelatinized corn starch.

Preferred celluloses include methylcellulose and hydroxypropyl methylcellulose, and preferred cellulose derivatives include hydropropylmethyl cellulose phthalate.

In a preferred embodiment, the secondary polymer is used to encapsulate the primary particle. Such encapsulation may be achieved by changing the pH, by adding a cross-linking agent, by heating, by spray drying, or by other suitable means. Example of cross-linking agents include sugar, acacia, cations, or gelatin.

Further provided by the subject invention are compositions produced by the above methods.

One composition encapsulating an oleophilic substance comprises an oleophilic substance, a first polymer which encapsulates the oleophilic substance to form a primary particle, and a second polymer which encapsulates at least one primary particle. The choices of primary and secondary polymers are as described above.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1--An illustration of a powder/beadlet showing the multi-microencapsulation structure formed in one embodiment of the present invention.

FIG. 2--A scanning electron micrograph (SEM) of a vitamin E powder (X100).

FIG. 3--SEM of a vitamin E powder (X200).

FIG. 4--SEM of sectioned vitamin E powder (X100).

FIG. 5--SEM of sectioned vitamin E powder (X500).

FIG. 6--SEM of vitamin A-palmitate (X50).

FIG. 7--SEM of vitamin A-palmitate (X200).

FIG. 8--SEM of sectioned vitamin A-palmitate (X300).

FIG. 9--SEM of sectioned vitamin A-palmitate (X500).

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described in terms of its preferred embodiments. These embodiments set forth to aid in the understanding of the invention, but are not to be construed as limiting. Throughout the specification, percentages are by weight percent and temperatures are °C, unless noted otherwise.

One inventive aspect of the subject invention is the production of high potency (generally from about 30 to about 90 weight percent) fat-soluble vitamins (such as A, D, E and K) in the form of dry powders and/or beadlets.

These vitamin powders and/or beadlets can be prepared by (1) emulsifying vitamin oils (such as vitamins A, D, E or K) in a polymeric solution (such as a cellulose or cellulose derivative), (2) dispersing vitamins (present as crystals) in a polymeric solution to form a suspension, or (3) dissolving and/or diluting fat-soluble vitamins in oil, then emulsifying the vitamin-oil solution in a polymeric solution to form an emulsion. Typically, the polymeric solution will be an aqueous solution.

Then, after the emulsifying, dispersing, dissolving and/or diluting, the emulsion or suspension is heated to a polymeric setting temperature (typically greater than 50°C) under mixing conditions to produce primary particles (e.g., microcapsules and/or microspheres). Alternatively, the polymer can be cross-linked. In each of these three above scenarios, the oleophilic substance is present as a liquid during at least a portion of the processing time, and typically throughout processing.

For ease in describing the subject invention, emulsifying, dispersing, dissolving and diluting will collectively be referred to as "incorporating."

The term "mixing conditions" refers to a state of imparted movement, such as that associated with stirring, shaking, agitating, jumbling, etc., which is vigorous enough to cause the emulsion or suspension to solidify as particles. Mixing conditions are readily determined by a skilled artisan who has read the present specification using known techniques, for example, by using an anchor stirrer, homogenizers, colloidal mills, microfluidizers, sonicators, or impellers (mechanical stirring). Particle size can be varied by changing the amount of imparted movement. For example, slow stirring will generally produce a larger particle size than will fast stirring. The examples which follow provide ample guidance for one skilled in the art to determine appropriate mixing conditions without undue experimentation.

Microcapsules are formed by a single encapsulation, whereas microspheres are conglomerates of multi-oil droplets embedded in a spherical or sphere-like matrix. The term "primary particle" as used herein refers to micro- and/or macro-particles produced by either heat inducing (setting), coacervating or cross-linking a polymer- containing emulsification. For convenience, cross-linking, coacervating and thermal setting will collectively be referred to as "solidifying."

Theoretically, preparation of oleophilic substances in a primary polymer-containing solution to form an emulsion or suspension can be performed at any temperature. However, the practical temperature range for this step depends on the nature of polymer chosen. For example, in preparing an HPMC emulsion, the preferred temperature should be between room temperature and no higher than 60°C The skilled artisan is readily able to determine an acceptable temperature range based on the components chosen.

The solidification step for making the primary particles is physically determined by the mechanism and process temperature. For instance, if solidification is caused by cross-linking, such as with an alginate emulsion cross-linking with calcium ions, temperature may not be critical. That is, processing can be effected at any temperature. However, when HPMC is chosen as the main polymer for the primary particles, and heating is the main mechanism utilized to make primary particles, temperature becomes important and must be maintained above 60°C throughout the whole process. Again, these parameters are determinable to the skilled artisan, having read the present disclosure.

Primary particles may then be further encapsulated with a secondary, or secondary and tertiary (depending on whether the primary particles are microcapsules or microspheres) polymeric layer(s) by the addition of a second polymer to the suspension followed by solidifying the second polymer (such as cross-linking by adding a cation, or by changing the pH) to form a secondary particle. The term "secondary particle" as used herein refers to a primary particle which has been further encapsulated or coated. The term "encapsulated" also includes the term "coated". Of course, multiple primary particles (at least 2) may be encapsulated or coated to form a single secondary particle.

Although the current method of production first solidifies the primary polymers by heating to form the primary particles and then simply coats or chemically cross-links the secondary polymers to form the secondary particles, alternate methods of solidifying may be utilized. Additionally, further encapsulations of the secondary particles, such as coating or polymerization around the secondary particles, may be effected.

Secondary and tertiary polymers are typically celluloses (e.g., methylcellulose or hydroxypropyl methylcellulose), cellulose derivatives (e.g., hydroxypropyl methylcellulose phthalate), alginates (e.g., sodium alginate or propylene glycol alginate), modified starches (e.g., pregelatinized corn starch or hydroxypropyl starch), calcium lactate, gelatins (e.g., fish gelatin), maltodextrins (e.g., dextrin having about 18 dextrose equivalent value, D.E.=18), or acacias. The final mixture may be sprayed dried or processed by any suitable drying techniques to powder or beadlet form which has high potency, is dry and free-flowing, and is suitable for tableting or encapsulation within soft or hard gelatin capsules. Such powders may also be used in food, animal feed, or other pharmaceutical applications, such as premix, suspension and emulsion.

The addition of secondary and/or tertiary polymer onto the primary particles is based on the same principle as described above. The proper temperatures, pH ranges, and ionic strengths for adding the second and/or third polymer varies depending on the types of materials and mechanisms used.

Experimental Detail

EXAMPLE 1

PAC High Potency Vitamin E Acetate Using Methocel E 15LV as the Primary Polymer, Sodium Alginate as the Second Polymer, and HPMC 6 cps as the Tertiary Polymer

______________________________________
FORMULA IA  FORMULA IB
INGREDIENTS    %           %
______________________________________
Vitamin E acetate
75 + 2% overage1
75 + 2% overage1
Methocel E 15LV2
13.0        20.0
Kelton LV/CaCloride3
2.0        2.0
Ratio 1:0.5
HPMC, 6 cps4
10.0        3.0
______________________________________
1 Overage is standard in the industry to ensure that the final
product contains at least the given percentage. Therefore, a 2% overage
was added.
2 Methocel E15LV refers to a special grade of hydroxypropyl
methylcellulose manufactured by Dow Chemical Co.
3 Keltone LV refers to the trade name for sodium alginate from the
Kelco, Division of Merck & Co. Inc.
4 HPMC, 6 cps refers to hydroxypropyl methylcellulose 2910, such as
that manufactured by SHIETSU Co. ("PHARMACOAT 606"). "Cps" is the
viscosity unit "centiopoise," is commonly referred to in the industry, an
is referenced throughout the specification.

PROCEDURE

1. Sodium alginate solution (5% w/w) was prepared in a 2 liter (l) beaker as follows:

______________________________________
Preparation of 5% sodium alginate
Time  Temperature
Stirrer speed
(min.)
(°C)
(rpm)     Amount
Comments
______________________________________
0     20                  1.27 l
Add water to beaker and
stir
5     20        1200      66.7 g
Add sodium al inate
25        2000            Heat suspension to 70°
C., and maintain temper-
ature and agitation until
the solution is used
______________________________________

2. Calcium chloride solution (5% by weight) was prepared in a 1 l beaker as follows:

______________________________________
Preparation of 5% calcium chloride
Time  Temperature
(min.)
(°C)
Stirrer  Amount
Comment
______________________________________
0               --       0.633 l
Add water to beaker
1               on       33.3 g
Add calcium chloride
2     22        on             Stir and maintain
temperature at 70°C until
used
______________________________________

3. HPMC, 6 cps solution (12% by weight) was prepared in a 5 l beaker as follows:

______________________________________
12% HPMC, 6 cps
Time  Temp.   Stirrer speed
(min.)
(°C)
(rpm)      Amount
Comments
______________________________________
0    21                 2.45 l
Add water to beaker and
heat to 90° C
32    90      1000       0.5 kg
Slowly add HPMC 6 cps
powder with agitation
52    86       200             Addition completed
Remove heating source
82    91      1000       1.22 l
Rapidly add cold water
(rapid cooling)
Cool to room temperature
while maintaining gentle
agitation until use
______________________________________

4. Methocel E15LV solution (10%) was prepared using the same procedure as described in step 3. Essentially, Methocel E15LV was dispersed in 90°C water, stirred and then uniformly dissolved in the water while the temperature was cooled.

5. Vitamin E acetate (an oil) was added to the Methocel solution according to the above formula, and homogenized using a colloidal mill until an emulsion having the smallest possible oil droplet size was reached. Although average droplet size tends to vary, droplets less than about 3 μm in diameter are satisfactory for most uses. Typically, average droplets range between about 0.5 and 1 μm in diameter, even though smaller diameters are generally preferred. (During emulsification, a cooling system was applied to maintain the temperature at approximately 25°C).

6. The emulsion was then heated to about 80-90°C while mixing slowly (at about 200 r.p.m.) with an anchor stirrer.

7. Warm (70°C) 5% alginate solution was then added and the mixture was mixed slowly (at about 200 revolutions per minute (r.p.m.) with an anchor stirrer) while maintaining temperature above 70°C

8. The mixture was maintained at about 70°C for approximately 15 minutes, and then cross-linked by adding 5% calcium chloride solution.

9.HPMC 6 cps 12% solution at room temperature (RT) was added in small aliquots while maintaining the temperature above 70°C

10. Water was then added to adjust viscosity to less than about 2,000 cps (in this particular instance 1,000 cps) for spray drying.

11. The solution was then spray dried under conventional conditions.

A specific vitamin E emulsion was prepared in a FRYMA processing unit (homogenizer, different types of mixers, and cooling and heating system) manufactured by Fryma, Inc., as follows:

__________________________________________________________________________
Preparation of the vitamin E emulsion and suspension
Time
Temp.
Anchor
Colloidal
(min.)
(°C)
stirrer
mill Dissolver
Amount
Comments
__________________________________________________________________________
0   26  on  --   --   6.5 kg
Add 10% Methocel solution to
vessel
10  26  --  --   --   3.83 kg
Add vitamin E acetate to above
solution
18  27  on  on   on       Start emulsification
23      on  on   on       Sample 1: particle size of oil
droplets 790 nm
28      on  on   on       Sample 2: particle size of oil
droplets 713 nm
33      on  on   on       Sample 3: particle size of oil
droplets 768 nm
33      on  --   --       Emulsification ended; begin heating
to 85°C and maintain a proper
agitation throughout the whole
process
110 35  on  --   --       Add sodium alginate solution (75°C)
115 83  on  --   --       Mix 15 minutes
130 82  on  --   --       Add calcium chloride solution
(75°C)
132 85  on  --   --       Add HPMC 6 cps solution (75°C)
145 85  on  --   --       Begin cooling
165 82  on  --   --       Mix at room temperature
195 22  on  --   --       Heat up to 75°C
245 19  on  --   --       Measure viscosity: 4300 cps
255 73  on  --   --   2 l Add water to adjust viscosity to
1000 cps
__________________________________________________________________________

Spray dry the above vitamin E suspension using a NIRO spray dryer; operation with air. This spray dryer is manufactured by Niro, Inc.

EXAMPLE 2A

PAC High Potency Vitamin E Acetate Using Methocel E15LV as the Primary Polymer and HPMCP HP-55S as the Secondary Polymer

______________________________________
85%    80%    75%  70%   65%  50%
INGREDIENTS  E      E      E    E     E    E
______________________________________
Vitamin E acetate
85     80     75   70    65   50
Methocel E15LV
10.0   13.4   16.7 20    23.4 33.4
HPMCP grade HP-55S*
5.0    6.6    8.3  10    11.6 16.4
______________________________________
Note: A 2% overage for Vitamin E acetate was used for each formula.
*To dissolve HPMCP, 4.5 ml of 0.5 N NaOH per gram of HPMCP was utilized.
Once HPMCP completely dissolved in the alkaline solution; water was added
to adjust the solution to 15% solid content.

PROCEDURE

1. HPMCP HP-55S solution (15% by weight) was prepared in a 100 l vessel as follows:

______________________________________
Preparation of 15% HPMCP HP 55s Solution
Time   Temp.
(min.) (°C)
Stirrer  Amount Comments
______________________________________
0      16       on       14.94 l
Add water into the vessel
5      15       on       300 g  Add sodium hydroxide
slowly
10     16       on              Addition ended
15              on       3.32 kg
Add HPMCP HP-55S
powder to above solution
with agitation
35     14       on              Addition ended, start
heating
215    65       on       3.57 l Add 70°C hot water
Stir the solution until
______________________________________
use

2. Methocel E15LV solution (10%) was prepared as in Example 1.

3. Vitamin E acetate was added to the Methocel solution according to the above formulas and homogenized to produce an emulsion as in Example 1.

4. The resulting emulsion was heated to 80-90°C with slow (200 r.p.m.) mixing with an anchor stirrer.

5. An amount of warm (70°C) 15% HPMCP solution was added. The amount added corresponded to the amount recited in percentage table shown above.

6. The temperature of above mixture was kept at about 80°C and cross-linked by adding HCl (0.1 N), with mixing, to shift the pH to approximately 5 (about 4.9-5.2).

7. The cross-linked solution was allowed to equilibrate for approximately 45 minutes.

8. The resulting cross-linked solution was then spray dried at the conditions shown below to form a powder.

__________________________________________________________________________
Spray drying of the vitamin E suspension
The suspension was pumped from the FRYMA processing unit to the
spray tower by a gear pump and then atomized by a rot atomizer from Niro,
Inc.
Set
Set Inlet
Inlet
Set outlet
Outlet
Pressure
Pressure
In at air
Time
Temp.
Temp.
Temp.
Temp.
Tower
Tower
flow in
(min.)
(°C)
(°C)
(°C)
(°C)
in mbar
in mbar
m3/n
Comments
__________________________________________________________________________
0  180     100      -5          Start up lower
50  180 181 100  101 -5  -3  1500
Start spray
drying
60  180 181 100  100 -5  -3  1500
62                               Spray drying
ended
__________________________________________________________________________

The "Set Pressure Tower" is the setting for the equilibrium condition in the dryer. In contrast, the "Pressure Tower" is the actual sure reached in the dryer during spray drying.

EXAMPLE 2B

PAC High Potency Vitamin E Acetate Using Methocel E15LV as the Primary Polymer and Fish Gelatin, Maltodextrin, Pregelatinized Corn Starch, Calcium Lactate, or Hydroxypropyl Starch as the Secondary Polymer

Following the procedure in Example 2A (with HPMCP being replaced by another secondary polymer), several different secondary

__________________________________________________________________________
Fish      Preglatinized
Calcium
Hydroxypropyl
Gelatin
Maltrin
Corn Starch
Lactate
Starch
INGREDIENTS
75% E
75% E
75% E  75% E
75% E
__________________________________________________________________________
Vitamin E Acetate
75   75   75    75    75
Methocel E15LV
16.7 16.7 16.7  16.7  16.7
Fish Gelatin
8.3  --   --    --    --
Maltrin M1801
--   8.3  --    --    --
Pregelatinized Corn
--   --   8.3   --    --
Starch
Calcium Lactate
--   --   --    8.3   --
Hydroxypropyl Starch
--   --   --    --    8.3
__________________________________________________________________________
1 Brand of maltodextrin (D.E. = 18).

Analysis of the five secondary polymers provided the following results using standard test procedures:

______________________________________
Fish  Maltrin PreGel         HP
Gelatin
M180    Starch  CaLactate
Starch
______________________________________
Flow   sec./100 g
27      23    28    17     39
(Agway)
Density
g/ml     0.34    0.39  0.33  0.50   0.34
Tapped g/ml     0.39    0.44  0.38  0.56   0.39
Density
Moisture
1.3      1.0     2.8   0.8   1.0
Color  W1E313   37.87   54.26 51.43 53.65  50.10
Y1E313   13.22   9.18  9.96  9.12   9.94
Static observed High    Medium
Low   Medium Very
High
Free Oil5
%        2.4     1.6   2.3   2.9    2.2
______________________________________
5 Free Oil refers to the percentage of unencapsulated Vitamin E, and
was determined as follows:

Procedure for Measuring Free Oil on Powder Surface

Procedure for Preparing Sample Solution

1. Transfer 0.250 g of powder (vitamin E 75%) to a suitable container.

2. Add 43.0 g of light mineral oil (Fisher).

3. Shake on a mechanical shaker at medium speed for 15 minutes.

4. Pass through a 0.45 μm filter.

5. Measure the UV absorption of the filtrate at 285 nm to determine the abs(sample). Compare against known vitamin E acetate standard (Std).

Procedure for Preparing Standard Solution

1. Weigh 150 mg vitamin E oil standard in a suitable container.

2. Add 86.0 g light mineral oil to above container.

3. Mix using a mechical shaker at medium speed for 15 minutes.

4. Remove 2.5 g of above solution and transfer to an appropriate container.

5. Add 43.0 g of light mineral oil to the container and shake for an additional 15 minutes.

6. Measure the u.v. absorbtion of above solution at 285 nm to determine abs(Std.).

Calculations: ##EQU1## % Free Oil in powder (% unencapsulated vitamin E)=X/(0.25 ×0.75)×100

Procedure for Evaluating Powder Suitability for Tabletting

The powders of the subject invention are useful in producing antioxidant tablets. To demonstrate their suitability and tabletting performance in antioxidant tablets, tablets were prepared at 4,000 lb pressure using a rotary press.

__________________________________________________________________________
TABLETTING PERFORMANCE OF VITAMIN E75% POWDERS IN
ANTIOXIDANT TABLETS AT 4000 LB PRESSURE USING ROTARY PRESS
__________________________________________________________________________
Ejection Force
lbs  47    40   41   38    43
Hardness Avg
scu  15    17.1 16.9 12.3  12.9
Range       11.7-16.9
15.6-18.3
15.8-18
11.1-13.6
11.8-13.6
Disintegration
minutes
15    15   20   14    14
Friability
%    0.03  0.07 0.09 0.08  0.09
__________________________________________________________________________

The above results were obtained using the following antioxidant formula:

__________________________________________________________________________
ANTIOXIDANT FORMULA
USING VITAMIN E57 BETATAB R AND C-90 GLOBAL
claim
%              kg/90 kg
Ingredients   tablet
overage
mg/tab
%    Batch
__________________________________________________________________________
BetaTab R 7.5%
6 mg
35   108  11.55
10.395
(Beta Carotene 7.5% Beadlets)
Vitamin C-90 Global
250 mg
5    292  31.23
28.107
Vitamin E 75% 200 IU
5    280  29.95
26.955
Microcel C              97   10.37
9.333
(Calcium Silicate)
Avicel PH 102           56   5.99 5.373
(Microcrystalline cellulose)
Polyplasdone XL         97   10.37
9.333
(Crospovidone)
Cab-O-Sil               5    0.54 0.486
(Colloidal Silicon Dioxide)
TOTAL                   935  100  90
__________________________________________________________________________

EXAMPLE 3

PAC High Potency E Formula III Containing Acacia

______________________________________
Ingredients        75% E   80% E
______________________________________
1. Vitamin E Acetate
75.0    80.0*
2. HPMC E15LV      15.0    12.0
3. Acacia          10.0    8.0
Total              100.0%  100.0%
______________________________________
*Additional 2% overage was added.

PROCEDURE

1. Gum acacia solution (20% by weight) was prepared in a 4 l beaker as follows:

______________________________________
Preparation of 20% gum acacia
Time (min.)
Temp. (°C)
Stirrer  Amount
Comments
______________________________________
0      21°C
on       2 l   Add water into beaker
151     39°C
on, slow 0.5 kg
Add gum acacia
175     36°C
on, fast       Addition completed
190     37°C
on, fast       Begin heating
208     63°C
on, slow
279     71°C
--             Add to emulsion
______________________________________

2. 10% Methocel E 15LV solution was prepared as in Example 1.

3. Vitamin E acetate was added to Methocel solution according to the above formulas and homogenized to produce an emulsion as in Example 1.

4. The resulting emulsion was heated to 80-90°C with slow (200 r.p.m.) agitation.

5. An appropriate amount of 20% acacia solution from step 1 was added.

6. The mixture from above was blended with gentle agitation for an additional 15 minutes while the temperature were maintained at 70-90°C

7. Spray the vitamin E suspensions at the following conditions.

__________________________________________________________________________
Spray drying of the vitamin E suspension
The suspension was pumped from the FRYMA processing unit to the spray
tower
by a gear pump and then atomized by a rot atomizer manufactured by Niro,
Inc.
Set
Set Inlet
Inlet
Set outlet
Outlet
Pressure
Pressure
In at air
Time
Temp.
Temp.
Temp.
Temp.
Tower
Tower
flow in
(min.)
(°C)
(°C)
(°C)
(°C)
in mbar
in mbar
m3/n
Comments
__________________________________________________________________________
0  180     100      -5          Start up lower*
50  180 181 100  101 -5  -3  1500
Start spray
drying
60  180 181 100  100 -5  -3  1500
62                               Spray drying
ended
__________________________________________________________________________
*Shorthand for start up the spray dryer from a lower inlet temperature. I
is standard procedure to start up a spray dryer at low temperature, then
gradually increase the inlet temperature to reach a proper outlet
temperature, and to establish an equilibrium condition.

EXAMPLE 4

PAC 30 % Vitamin A Products Using Hydroxypropyl Methylcellulose as the Primary Polymer, and Sodium Alginate, HPMCP HP-55, or Acacia as the Secondary Polymer

______________________________________
Ingredient     Formula I Formula II
Formula III
______________________________________
Vitamin A Palmitate
30.0 + 2.5*
30.0 + 2.5*
30.0 + 2.5*
Butylated Hydroxyanisole
1.0       1.0       1.0
(BHA)
Butylated Hydroxytoluene
3.0       3.0       3.0
(BHT)
Methocel E15LV 50.8      42.4      50.8
HPMCP, HP-55S  --        21.1      --
Acacia         --        --        12.7
Sodium Alginate
3.4       --        --
Calcium Chloride
1.7       --        --
PHARMACOAT 606 7.6       --        --
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Note: *% Overage

PROCEDURE

PAC FORMULATION I

Composition

______________________________________
Material           content (%)
weight (kg)
______________________________________
Vitamin A palmitate 1.7 MIU/g
32.47     1.30
BHA                1         0.04
BHT                3         0.12
METHOCEL E15LV premium
50.82     2.03
Sodium alginate    3.39      0.136
Calcium chloride   1.69      0.068
PHARMACOAT 606     7.62      0.305
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General

All the solutions were prepared using degassed deionized water under nitrogen. Vitamin A palmitate was shielded from light.

Preparation of a 12% solution of METHOCEL E15LV

Water (8 l) was heated to 85°C METHOCEL E15LV powder (2.03 kg) was slowly added into the water while mixing with rapid agitation until a uniform suspension was obtained and thoroughly dispersed. Additional cold water (6.89 l) was quickly added to the suspension and the temperature was cooled to 25°C

Preparation of a 5% solution of sodium alginate

Sodium alginate powder (0.136 kg) was added into 2.58 liters of cold water with proper agitation and heated to 80-90°C The solution was kept at 70°C until used.

Preparation of a 5% solution of calcium chloride

Calcium chloride (0.068 kg) was dissolved in 1.29 l of water. The solution was kept at room temperature until used.

Preparation of a 12% solution of PHARMACOAT 606

Water (0.75 l) was heated to 90°C PHARMACOAT 606 powder (0.305 kg) was slowly added into the water while mixing with proper agitation until a uniform suspension was formed. Cold water (1.50 l) was added quickly to the suspension and the temperature was cooled to 25°C The solution was maintained at room temperature with gentle agitation until used.

Preparation of the emulsion/suspension BHA (0.04 kg) and 0.12 kg BHT were added to 1.3 kg vitamin A palmitate and mixed until a clear solution was formed. The resulting solution was added to the METHOCEL E15LV solution and emulsified for 30 minutes with the colloidal mill. (The oil droplet size measured using a MALVERN Autosizer was 757 nm). The emulsion was then heated to 75°C while slowly mixing (200 r.p.m.) with an anchor stir bar to form a suspension. The 70°C sodium alginate solution was added to the suspension and stirred for 15 minutes. Calcium chloride solution was added, and the mixture was cooled. PHARMACOAT solution was added at room temperature and mixed for 10 minutes. The mixture was then heated to 65°C while mixing slowly with an anchor stir bar. (the suspension had a viscosity of 11,400 cps/65°C). The suspension was then diluted with 2 l hot water to adjust the viscosity to 2,500 cps/65°C

Spray drying

See below (spray dry results are shown in FIGS. 6-9).

FORMULATION II

Composition

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Material           content (%)
weight (kg)
______________________________________
Vitamin A palmitate 1.7 MIU/g
32.47     1.46
BHA                1         0.045
BHT                3         0.135
METHOCEL E15LV premium
42.44     1.91
HPMCP 55           21.09     0.95
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General

All the solutions were prepared using degassed deionized water under nitrogen. Vitamin A palmitate was shielded from light.

Preparation of a 12% solution of METHOCEL E15LV

Water (8 l) was heated to 85°C METHOCEL E15LV powder (2.03 kg) was slowly added into the water while mixing with rapid agitation until a uniform suspension was obtained and thoroughly dispersed. Additional cold water (6.89 l) was quickly added to the suspension and the temperature was cooled to 25°C

Preparation of a 15% solution of HPMCP

HPMCP powder (0.95 kg) was added to 4.28 l of 0.5 N NaOH with proper agitation and heated to 70°C Hot (70°C) water (1.1 l) was added after the powder completely dissolved. The solution was kept at 70°C until used.

Preparation of the emulsion/suspension

BHA (0.045 kg) and 0.135 kg BHT were added to 1.46 kg vitamin A palmitate and mixed until a clear solution was formed. The solution was added to the METHOCEL E solution and emulsified for 30 minutes using a colloidal mill. The oil droplet size measured using a particle size analyzer (MALVERN Autosizer 2C manufactured by Malverne Instruments, Inc.) was 888 nm. Then, the emulsion was heated to 75°C while slowly stirring (200 r.p.m.) with an anchor stir bar to form a suspension. The 70°C HPMCP solution was added to the suspension and continuously stirred with an anchor agitator. The pH was adjusted to 6.9 with 0.5 l of 1 N NaOH (pH before : 5.28). The resulting suspension had a viscosity of 500 cps/70°C

Spray drying

See below.

FORMULATION III

Composition

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Material           content (%)
weight (kg)
______________________________________
Vitamin A palmitate 1.7 MIU/g
32.47     1.46
BHA                1         0.045
BHF                3         0.135
METHOCEL E15LV premium
50.82     2.29
Gum acacia         12.7      0.58
______________________________________

General

All solutions were prepared using degassed deionized water under nitrogen. Vitamin A palmitate was shielded from light.

Preparation of a 10% solution of METHOCEL E

Water (6.2 l) was heated to 85°C METHOCEL E15LV powder (2.29 kg) was slowly added into the water while mixing with rapid agitation until a uniform suspension was obtained. Additional cold water (14.41 l) was quickly added to the suspension and the temperature was cooled to 25°C

Preparation of a 20% solution of gum acacia

Gum acacia powder (0.58 kg) was dissolved to 2.32 l cold water and heated to 70°C The solution was kept at 70°C until used.

Preparation of the emulsion/suspension

BHA (0.045 kg) and 0.135 BHT were added to 1.46 kg vitamin A palmitate and mixed until a clear solution was formed. The solution was added to the METHOCEL E solution and emulsified for 30 minutes with the colloidal mill. The oil droplet size measured using MALVERN Autosizer 2C was 854 nm. The emulsion was then heated to 75°C while mixing with an anchor bar to form a suspension. The 70°C gum acacia solution was added to the suspension and stirred with an anchor agitator. The pH was adjusted to 7.2 with 40 ml of 0.5 N NaOH (pH before: 6.37). The resulting suspension had a measured viscosity of 1060 cps/70°C

Spray drying

See below.

Spray Drying Conditions for Formulations I, II and III

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Feed          Inlet Air
Outlet Air
Inlet
Wheel
Formulation
Temp.
Viscosity
Temp.
Temp.
Air Flow
Speed
Number
(°C)
(cps) pH (°C)
(°C)
m3 /h
(rpm)
__________________________________________________________________________
I     65   2,500/65°C
-- 165  100  1,500
8,500
II    70     500/70°C
6.9
165  100  1,500
8,500
III   70   1,060/70°C.
7.2
160  100  1,500
8,500
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2% silicic acid (type FK 320 DS) was added in each trial.

Pressure inside the tower was always about -4 mbar.

The subject invention has been described in terms of its preferred embodiments. However, one skilled in the art will recognize various alternative embodiments having read the specification. These variations are to be considered within the scope and spirit of the invention which is only to be limited by the claims which follow and their equivalents.

Claims

1. A method for procucing a composition which comprises

a) incorporating vitamin E into an aqueous solution having a hydroxypropyl methylcellulose primary polymer dissolved therein, to form an aqueous mixture of the vitamin E in the solution;

b) heat setting the primary polymer under mixing conditions while the primary polymer is in the aqueous mixture, to encapsulate the vitamin E within the primary polymer and form a primary particle in the aqueous mixture; and

c) drying the aqueous mixture produced in step b) to yield the composition.

2. The method according to claim 1 wherein said vitamin E is vitamin E acetate.

3. A method for producing a composition which comprises

a) incorporating vitamin E into an aqueous solution having a hydroxypropyl methylcellulose primary polymer dissolved therein, to form an aqueous mixture of the vitamin E in the solution;

b) heat setting the primary polymer under mixing conditions while the primary polymer is in the aqueous mixture, to encapsulate the vitamin E within the primary polymer and form a primary particle in the aqueous mixture;

c) adding a secondary polymer to the aqueous mixture under mixing conditions to farther encapsulate at least one primary particle within the secondary polymer, and

d) drying the aqueous mixture produced in step c) to yield the composition.